Control moment gyroscope assembly and method for making the same

ABSTRACT

A control moment gyroscope assembly including, but not limited to, a rotor that includes a shaft, a primary rim and a web that connects the shaft to the primary rim. The rotor is made from a metal material and is adapted to spin about the shaft. The control moment gyroscope assembly further includes a secondary rim that is made of the metal material and that is disposed around the rotor. The secondary rim is configured to compress the rotor in the direction of the shaft.

TECHNICAL FIELD

The present invention generally relates to gyroscopes and moreparticularly to control moment gyroscopes for spacecraft.

BACKGROUND

Gyroscopes are spinning bodies, such as wheels or discs, that generateangular momentum as they spin about an axle. The principles ofconservation of angular momentum make gyroscopes resistant to torquesthat are applied to their axles. Because of their tendency to reliablyremain in a given orientation when spinning, gyroscopes have been usedin various navigation systems.

One common application has been to use gyroscopes to control themovement of spacecraft operating in a weightless environment, such asthat encountered while in orbit around the earth. The attitude of aspacecraft is controlled and or maneuvered gyroscopically by followingthe law of conservation of momentum. CMGs exchange their momentum withthe momentum of the spacecraft. They do this by torquing the gimbal axisof the CMG to change the direction of the momentum vector of the CMGwhich then changes the momentum of the spacecraft. This changes thevelocity of the spacecraft. Because gyroscopes are resistant to changesin the angle of their axles, a torque applied to the axle by aspacecraft operating in zero gravity will result in movement of thespacecraft around the gyroscope. In this manner, the attitude andorientation of the spacecraft can be controlled. Gyroscopes that areused for this purpose are known as control moment gyroscopes. The fasterthat a control moment gyroscope spins and the more mass that a controlmoment gyroscope has, the more resistant a control moment gyroscope willbe to a torque applied to its axle.

The control moment gyroscope typically includes a rotor disposed withina housing. The rotor typically includes a shaft that serves as therotor's axle, a rim that has a circular or ring-like configuration andwhich comprises the majority of the rotor's mass, and a web thatconnects the rim to the shaft. The shaft is configured to mount therotor to the housing in a manner that permits the rotor to spin withrespect to the housing.

The web may be is connected to the shaft and to the rim by one or moreweld joints. As the rotor spins, the weld joints are placed in tension.The maximum speed at which the rotor can spin is therefore limited bythe amount of tension stress that the weld joints can tolerate.Additionally, when torque is applied to the shaft to move thespacecraft, the weld joints alternately cycle through tension andcompression due to the spinning of the rotor. Such cycling throughalternate states of tension and compression can fatigue the weld jointsand reduce their tolerance to tension which can, in turn, reduce themaximum rotational speed of the rotor.

BRIEF SUMMARY

Embodiments of a control moment gyroscope assembly and a method formaking a control moment gyroscope assembly are disclosed herein.

In an embodiment, the control moment gyroscope assembly includes, but isnot limited to, a rotor that includes a shaft, a primary rim and a webthat connects the shaft to the primary rim. The rotor is made of a metalmaterial and is adapted to spin about the shaft. The control momentgyroscope assembly also includes a secondary rim that is made of themetal material and that is disposed around the rotor. The secondary rimis configured to compress the rotor in the direction of the shaft.

In another embodiment, the control moment gyroscope assembly includes,but is not limited to, a rotor that includes a shaft, a primary rim, aweb disposed between the shaft and the primary rim, a first weld jointjoining the web to the shaft and a second weld joint joining the web tothe primary rim. The rotor is made of steel and is adapted to spin aboutthe shaft. The control moment gyroscope assembly further includes asecondary rim that is made of steel and that is thermally coupled to theprimary rim such that the primary rim and the secondary rim are in aninterference fit with respect to one another. The interference fitcauses the secondary rim to compress the rotor in the direction of theshaft such that the first weld joint and the second weld joint are incompression as the rotor spins.

In another embodiment, a method for assembling the control momentgyroscope includes, but is not limited to, the step of providing a rotorand a secondary rim. The rotor and the secondary rim are each made ofsteel. The rotor includes a primary rim that has an outer diameter. Thesecondary rim has an inner diameter. The outer diameter exceeds theinner diameter when the primary rim and the secondary rim are at thesame temperature. The method also includes the step of heating thesecondary rim until the secondary rim expands to a state where the innerdiameter exceeds the outer diameter. The method also includespositioning the secondary rim around the primary rim while the innerdiameter exceeds the outer diameter. The method also includes the stepof cooling the secondary rim, causing the secondary rim to contractaround the primary rim and thereby create an interference fit betweenthe primary rim and the secondary rim that compresses the primary rim inan inward direction.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will hereinafter be described in conjunction withthe following drawing figures, wherein like numerals denote likeelements, and

FIG. 1 is a simplified cross sectional view of a prior art controlmoment gyroscope;

FIG. 2 is a simplified cross sectional view of an embodiment of acontrol moment gyroscope made in accordance with the teachings of thepresent disclosure;

FIG. 3 is a simplified plan view illustrating the relative diameters ofa primary rim and a secondary rim;

FIGS. 4A-C are a series of fragmentary schematic cross-sectional viewsschematically illustrating the interference fit between the secondaryand the primary rims and the resulting compression on the primary rim;

FIG. 5 is a fragmentary side view of a portion of the rotor of FIG. 2schematically illustrating an initial stage of a swaging process tosecure the secondary rim to the primary rim;

FIG. 6 is a fragmentary side view of the portion of the rotor depictedin FIG. 5 schematically illustrating an arrangement wherein thesecondary rim is secured to the primary rim via a swaged lip of theprimary rim;

FIG. 7 is a fragmentary side view of a portion of the rotor of FIG. 2schematically illustrating an initial stage of a welding process tosecure the secondary rim to the primary rim;

FIG. 8 is a fragmentary side view of the portion of the rotor depictedin FIG. 7 schematically illustrating an arrangement wherein thesecondary rim is secured to the primary rim via a welded joint;

FIG. 9 is a simplified cross sectional view of an alternate embodimentof a control moment gyroscope made in accordance with the teachings ofthe present disclosure; and

FIG. 10 is a block diagram illustrating the steps of an embodiment of amethod for making a rotor suitable for use in a control moment gyroscopein accordance with the teachings of the present disclosure.

DETAILED DESCRIPTION

The following detailed description is merely exemplary in nature and isnot intended to limit the invention or the application and uses of theinvention. Furthermore, there is no intention to be bound by any theorypresented in the preceding background or the following detaileddescription.

Embodiments of a control moment gyroscope and methods for making acontrol moment gyroscope are disclosed herein. It should be understoodthat the teachings disclosed herein are not limited to applications withcontrol moment gyroscopes, but instead are equally applicable toReaction Wheel Assemblies (RWAs) and momentum wheels. The control momentgyroscope includes a housing, a rotor, and various machine components.The housing is configured to enclose the rotor and to support the rotorin a manner that permits the rotor to spin with respect to the housing.The rotor comprises steel and includes a shaft, a rim (hereinafter, the“primary rim”) and a web that links the shaft to the primary rim. Theshaft serves as an axle to support the rotor in a spinning relationshipwith the housing. The primary rim is generally configured as a ring andcomprises a majority of the mass of the rotor. The web is attached tothe shaft and to the primary rim via welded joints (hereinafter “weldjoints”). The machine components are attached to the housing and areconfigured to spin the rotor within the housing.

A secondary rim, generally configured as a ring and comprising steel, ismounted to the rotor adjacent an outer surface of the primary rim. Theprimary rim has an outer diameter that exceeds the inner diameter of thesecondary rim. Thus, the secondary rim and the primary rim are arrangedin an interference fit with respect to one another. Due to theinterference fit, the secondary rim inwardly compresses the primary rimwhich, in turn, compresses the weld joints that hold the primary rim tothe web and that hold the web to the shaft. In some embodiments, thecompression acting on the primary rim is sufficient to ensure that theweld joints remain in compression throughout the entire operationalrange of rotational speeds of the rotor. By maintaining the weld jointsin a state of compression, the rotor is enabled to spin at speeds thatare greater than could be achieved without the secondary rim. This, inturn, enables the rotor to generate greater angular momentum whichprovides greater torque for maneuvering the spacecraft. Additionally,the compression of the weld joints greatly reduces, and in some cases,eliminates the occurrence of the weld joint fatigue which wouldotherwise occur as torque is applied to the shaft of the rotor duringspacecraft maneuvers. Furthermore, other elements of the primary rim andthe web will also be in compression and will gain similar advantage.This is helpful where there are places of high stress.

Because both the primary rim and the secondary rim are made of steel,the two components can be welded together. Such welding fixes thesecondary rim with respect to the primary rim and inhibits the secondaryrim from moving with respect to the primary rim, or from becomingdisplaced from the primary rim as the rotor spins at elevated rates ofrotation. This fixed relationship greatly enhances the stability of therotor and is made possible by the fact that the primary rim and thesecondary rim are both made of the same metal material. The secondaryrim could not be effectively welded to the primary rim if the two rimswere comprised of differing metal materials. It should be understoodthat, while the discussion contained herein described the variouscomponents of the rotor and the secondary rim as being made of steel,materials other than steel could be used providing they have similar oreven better high strength features.

One method of mounting the secondary rim to the primary rim is tothermally couple the rims together. This entails heating the secondaryrim and causing it to expand until its inner diameter exceeds the outerdiameter of the primary rim. In some embodiments, the primary rim issimultaneously cooled, causing it to contract and thereby facilitate themounting of the secondary rim onto the primary rim. Once the secondaryrim is in place about the primary rim, the secondary rim is allowed tocool (and the primary rim is allowed to warm if it has been cooled),thus causing the secondary rim to contract around the primary rim. Thiscontraction of the secondary rim back to its pre-heating dimensioncreates the interference fit discussed above and causes the secondaryrim to inwardly compress the primary rim.

A greater understanding of the embodiments of the control momentgyroscope assembly and the methods for making the control momentgyroscope assembly may be obtained through a review of the illustrationsaccompanying this application together with a review of the detaileddescription that follows.

FIG. 1 is a simplified cross sectional view of a prior art controlmoment gyroscope 16. Prior art control moment gyroscope 16 includes arotor 18 and a housing 20. Rotor 18 is made of steel and includes ashaft 22, a primary rim 24 having an underside 26, and a web 28 joiningprimary rim 24 to shaft 22. Web 28 is generally configured as a shelland is attached to shaft 22 via weld joints 30 and 31 and to primary rim24 via weld joints 32 and 33. Housing 20 includes machine components 34which each include a bearing 36. Each bearing 36 is configured toreceive an end portion of shaft 22. One or both machine components 34include a motor (not shown) that engages the end portion(s) of shaft 22and which cause rotor 18 to rotate.

As illustrated, rotor 18 employs only a single steel rim, primary rim24. Primary rim 24 is not inwardly compressed and therefore does notinwardly compress weld joints 30, 31, 32 or 33. Accordingly, as rotor 18spins, weld joints 30, 31, 32, and 33 are placed in tension. As torqueis applied to prior art control moment gyroscope 16, as indicated byarrows 38 and 40, some of the weld joints will be placed in tension andsome will be placed in compression. With respect to the weld jointslocated above line 1-1, as torque is applied in the direction indicatedby arrow 38, initially weld joints 30 and 32 will be placed in tensionwhile weld joints 31 and 33 will be placed in compression. When rotor 18rotates one hundred and eighty degrees, the situation will reverse—weldjoints 30 and 32 will be placed in compression while weld joints 31 and33 will be placed in tension. When rotor 18 rotates an additional onehundred and eighty degrees, the situation will reverse again. This cycleof tension and compression will repeat itself until the torque indicatedby arrow 38 abates. This cycling of the weld joints between tension andcompression can, over time, fatigue the weld joints.

FIG. 2 is a simplified cross sectional view of an embodiment of acontrol moment gyroscope 42 made in accordance with the teachings of thepresent disclosure. Control moment gyroscope 42 includes a rotor 44 anda housing 46. Rotor 44 is made of steel and includes a shaft 48, aprimary rim 50 having an underside 52, and a web 54 joining primary rim50 to shaft 48. Web 54 is generally configured as a shell and isattached to shaft 48 via weld joints 56 and 57 and to primary rim 50 viaweld joints 58 and 59. Housing 46 includes machine components 60 whicheach include a bearing 62. Each bearing 62 is configured to receive anend portion of shaft 48. One or both machine components 60 include amotor (not shown) that engages the end portion(s) of shaft 48 and whichcause rotor 44 to rotate.

Rotor 44 further includes a secondary rim 53 positioned adjacent primaryrim 50 and thermally coupled thereto to create an interference fitbetween primary rim 50 and secondary rim 53. Accordingly, secondary rim53 inwardly compresses primary rim 50 and, by extension, inwardlycompresses weld joints 56, 57, 58, and 59. This compression of weldjoints 56, 57, 58, and 59 permits rotor 44 to spin at higher speeds thanwould be possible without such compression. In the absence of thiscompression, the rotational speed of rotor 44 would be limited by theability of weld joints 56, 57, 58, and 59 to tolerate tension. Becauseweld joints 56, 57, 58, and 59 do not enter a state of tension, theirability to tolerate tension is eliminated as a limiting factor on therotational speed of rotor 44. It should be understood that weld jointsmay not be employed in all designs. Rather, the primary rim, the web andthe shaft may be integral, i.e., made from one piece of metal. In such acase, high stress will develop in the web near the shaft and under theprimary rim. In such a case, the secondary rim will also function toreduce stresses in this design as it does in welded configurations.

The presence of secondary rim 53 also avoids the cycling of weld joints56, 57, 58, and 59 through alternating states of compression and tensionwhen a torque, represented by arrows 64 and 66, is applied to controlmoment gyroscope 42. With respect to the portion of control momentgyroscope 42 disposed above line 2-2, immediately prior to theapplication of the torque, weld joints 56, 57, 58, and 59 are each in astate of compression due to the interference fit between secondary rim53 and primary rim 50. When the torque represented by arrow 64 isapplied to control moment gyroscope 42, weld joints 56 and 58 experiencea diminution in compression, but do not enter a state of tension.Correspondingly, weld joints 57 and 59 experience an increase incompression when the torque is applied. As rotor 44 rotates one hundredand eighty degrees, the situation reverses—weld joints 56 and 58experience an increase in compression while weld joints 57 and 59experience a diminution in compression, but do not enter a state oftension. Upon the continued rotation of rotor 44 by an additional onehundred and eighty degrees, the situation reverses again. By maintainingthe weld joints in a state of compression, they avoid entering a stateof tension even when a torque is applied to rotor 44. Because the weldjoints do not cycle through states of compression and tension, thefatigue experienced by weld joints 30, 31, 32, and 33 of prior artcontrol moment gyroscope 16 (see FIG. 1) is reduced or avoidedaltogether.

FIG. 3 is a simplified plan view illustrating the relative diameters ofprimary rim 50 and secondary rim 53. As illustrated, when primary rim 50and secondary rim 53 are at the same temperature, primary rim 50 has anouter diameter O.D. that is greater than the inner diameter I.D. ofsecondary rim 53.

FIGS. 4A-C are a series of fragmentary, schematic cross sectional viewsschematically illustrating the interference fit between secondary rim 53and primary rim 50 and the resulting compression on primary rim 50. InFIG. 4A, primary rim 50 is illustrated at a position that isrepresentative of its distance from shaft 48 when primary rim 50 is notconstrained by secondary rim 53. Secondary rim 53 is illustrated inclose proximity to primary rim 50 and at a position with respect toshaft 48 that is representative of its radial distance from shaft 48.Distance X represents the radial distance of underside 52 from shaft 48prior to thermally coupling secondary rim 53 around primary rim 50.

In FIG. 4B, rotor 44 is not spinning, secondary rim 53 has been mountedto primary rim 50 and secondary rim 53 is compressing primary rim 50inwardly towards shaft 48. A series of elongate arrows pointing in adownward direction have been illustrated to depict the compressive forceexerted by secondary rim 53 on primary rim 50. This compression, inturn, compresses weld joints 56, 57, 58, and 59. The distance fromunderside 52 to shaft 48 has diminished from X to X′ due to thecompression.

In FIG. 4C, rotor 44 is spinning. This causes primary rim 50 andsecondary rim 53 to expand under the centrifugal force caused by therotation of rotor 44. This expansion causes the distance from underside52 to shaft 48 to expand from X′ to X″. As primary rim 50 and secondaryrim 53 expand, secondary rim 53 continues to apply a compressive forceon primary rim 50, although such compressive force is smaller than thecompressive force applied by secondary rim 53 in FIG. 4B. This isbecause the centrifugal force acting on secondary rim 53 is greater thanthe centrifugal force acting on primary rim 50 due to secondary rim 53being positioned a greater distance from the axis of rotation (shaft 48)than primary rim 50.

An additional consideration is thermal expansion. Rotor 44 willtypically heat up as it spins. Its increased temperature will correspondto the rate of rotation. This heat will cause both primary rim 50 andsecondary rim 53 to expand. Accordingly, constructing primary rim 50 andsecondary rim 53 out of the same material ensures that these twocomponents will expand at the same rate, thereby making the compressiveforce acting on primary rim 50 more predictable than it would be ifdifferent materials were used.

FIG. 5 is a fragmentary side view of a portion of rotor 44 schematicallyillustrating an initial stage of a swaging process to secure secondaryrim 53 to a primary rim 50′. As illustrated, primary rim 50′ includes ashoulder 68. Shoulder 68 serves to prevent secondary rim 53 from slidingpast an end of primary rim 50′ when secondary rim 53 is thermallycoupled to primary rim 50′. Once secondary rim 53 is seated againstshoulder 68, a press 70 is compressed against a side 72 of primary rim50′. The force applied by press 70 is sufficient to deform or swage side72 to form a lip which inhibits secondary rim 53 from moving laterallywith respect to primary rim 50′.

FIG. 6 is a fragmentary side view of the portion of rotor 44 depicted inFIG. 5 schematically illustrating an arrangement wherein secondary rim53 is secured to primary rim 50′ via a swaged lip 74 of primary rim 50′.Swaged lip 74 and shoulder 68 cooperate to ensure that there is nolateral movement of secondary rim 53 with respect to primary rim 50′ asrotor 44 rotates.

FIG. 7 is a fragmentary side view of a portion of rotor 44 schematicallyillustrating an initial stage of a welding process to secure secondaryrim 53 to primary rim 50. Once secondary rim 53 has been thermallycoupled to primary rim 50, welding torches 76 are used to melt portionsof secondary rim 53 and primary rim 50 such that their respective meltedportions combine to form a weld joint.

FIG. 8 is a fragmentary side view of the portion of rotor 44 depicted inFIG. 7 schematically illustrating an arrangement wherein secondary rim53 is secured to primary rim 50 via a welded joint 78. Welded joint 78inhibits lateral movement of secondary rim 53 with respect to primaryrim 50 as rotor 44 rotates. Such a welded arrangement is possiblebecause primary rim 50 and secondary rim 53 are both comprised of thesame material.

FIG. 9 is a simplified cross sectional view of an alternate embodimentof a control moment gyroscope 42′ made in accordance with the teachingsof the present disclosure. With continuing reference to FIG. 2, controlmoment gyroscope 42′ is similar to control moment gyroscope 42, theprimary difference being that web 54′ of control moment gyroscope 42′ isconfigured as a disc whereas web 54 of control moment gyroscope 42 isconfigured as a shell having a generally oval configuration. Configuringthe web as a disc rather than a shell may permit rotor 44′ to spin morerapidly than rotor 44.

FIG. 10 is a block diagram illustrating the steps of an embodiment of amethod 80 for making a rotor suitable for use in a control momentgyroscope in accordance with the teachings of the present disclosure.

At block 82, a rotor and a secondary rim are provided, each constructedof steel. The rotor includes a primary rim having an outer diameter thatis smaller than an inner diameter of the secondary rim.

At block 84, the secondary rim is heated until it expands to a statewhere its inner diameter exceeds the outer diameter of the primary rim.Such heating of the secondary rim may be accomplished through anysuitable means including, for example, heating the secondary rim in afurnace.

At block 86, the primary rim is cooled while the secondary rim isheated. Cooling the primary rim causes it to contract, thus reducing itsouter diameter, and thereby facilitating the mounting of the secondaryrim to the primary rim. The cooling of the primary rim can beaccomplished by any suitable means including, for example, immersing theprimary rim in a cooled liquid. In other embodiments of method 80, thiscooling step may be omitted.

At block 88, once the secondary rim has expanded and the primary rim hascontracted to the point where the inner diameter of the secondary rim islarger than the outer diameter of the primary rim, the secondary rim ispositioned around the primary rim.

At block 90, the secondary rim is allowed to cool and the primary rim isallowed to warm up. As the secondary rim cools it will contract and asthe primary rim warms up, it will expand. Once both rims are at the sametemperature, the secondary rim will be arranged in an interference fitwith respect to the primary rim and will inwardly compress the primaryrim.

While at least one exemplary embodiment has been presented in theforegoing detailed description of the invention, it should beappreciated that a vast number of variations exist. It should also beappreciated that the exemplary embodiment or exemplary embodiments areonly examples, and are not intended to limit the scope, applicability,or configuration of the invention in any way. Rather, the foregoingdetailed description will provide those skilled in the art with aconvenient road map for implementing an exemplary embodiment of theinvention. It being understood that various changes may be made in thefunction and arrangement of elements described in an exemplaryembodiment without departing from the scope of the invention as setforth in the appended claims.

What is claimed is:
 1. A control moment gyroscope assembly comprising: arotor including a shaft, a primary rim and a web connecting the shaft tothe primary rim, the rotor comprising a metal material and being adaptedto spin about the shaft; and a secondary rim configured as a singlering, comprised of the metal material and disposed around the rotor, thesecondary rim configured to compress the rotor in a direction of theshaft, wherein the secondary rim is welded to the primary rim.
 2. Thecontrol moment gyroscope assembly of claim 1, wherein the web isconnected to the shaft via a weld joint, and wherein the secondary rimis configured to compress the rotor in a manner that places the weldjoint in compression.
 3. The control moment gyroscope assembly of claim2, wherein the secondary rim is configured to compress the rotor in amanner that maintains the weld joint in compression as the rotor spins.4. The control moment gyroscope assembly of claim 1, wherein the web isconnected to the primary rim via a weld joint, and wherein the secondaryrim is configured to compress the rotor in a manner that places the weldjoint in compression.
 5. The control moment gyroscope assembly of claim4, wherein the secondary rim is configured to compress the rotor in amanner that maintains the weld joint in compression as the rotor spins.6. The control moment gyroscope assembly of claim 1, wherein thesecondary rim is disposed around and adjacent an outer surface of theprimary rim.
 7. The control moment gyroscope assembly of claim 6,wherein the secondary rim is in an interference fit with the primaryrim.
 8. The control moment gyroscope assembly of claim 6, wherein thesecondary rim is thermally coupled to the primary rim.
 9. The controlmoment gyroscope assembly of claim 1, wherein the metal material issteel.
 10. The control moment gyroscope assembly of claim 1, wherein theweb is configured as a shell.
 11. The control moment gyroscope assemblyof claim 1, wherein the web is configured as a disc.
 12. The controlmoment gyroscope assembly of claim 1, wherein the secondary rim iswelded to the rotor.
 13. The control moment gyroscope assembly of claim1, wherein the secondary rim is disposed around the primary rim andwherein the primary rim includes a swaged lip that inhibits thesecondary rim from separating from the primary rim.
 14. The controlmoment gyroscope assembly of claim 1, wherein the secondary rim isdisposed around the primary rim and wherein the primary rim includes ashoulder that inhibits the secondary rim from separating from theprimary rim.
 15. A control moment gyroscope assembly comprising: a rotorincluding a shaft, a primary rim, a web disposed between the shaft andthe primary rim, a first weld joint joining the web to the shaft and asecond weld joint joining the web to the primary rim, the rotorcomprising steel and being adapted to spin about the shaft; and asecondary rim configured as a single ring, comprised of steel andthermally coupled to the primary rim such that the primary rim and thesecondary rim are in an interference fit with respect to one another andwherein the interference fit causes the secondary rim to compress therotor in a direction of the shaft such that the first weld joint and thesecond weld joint are in compression as the rotor spins, the secondaryrim also welded to the primary rim.
 16. The control moment gyroscopeassembly of claim 15, wherein the web is configured as a shell.
 17. Thecontrol moment gyroscope assembly of claim 15, wherein the web isconfigured as a disc.